Recycled plastic composite composition

ABSTRACT

A composition for a recycled plastic composite composition, and a method of making the composite composition, is provided. The composite composition includes recycled EVA from 30% to 80% and a stone powder from 20% to 70%; percentages by weight.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part application of U.S. application Ser. No. ______, entitled “A Recycled Plastic Composite Composition,” which was filed concurrently herewith, which application claims priority under 35 U.S.C. §119(e) to Chinese Patent Application Nos. CN201210055616.X, filed Mar. 5, 2012, and CN201210055620.6, filed Mar. 5, 2012.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates o a resin article, particularly to a composite composition for a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene), as well as to a process for the heat-pressing of a recycled plastic composite.

2. Background Information

Currently the problem in the resin article and the related art is the high cost of the raw material, the blank will be modified by the repairing, low production efficiency, the repeated usage of the corresponding mold being limited (about 300 times), and the lower surface smoothness, heat resistance, and toughness of the resin article.

SUMMARY OF THE INVENTION

The present invention provides a formulation for a recycled plastic composite composition comprising in the terms of weight percent: recycled EVA from 30% to 80% and a stone powder from 20% to 70%. Preferably, said composition comprises in the terms of weight percent: the recycled EVA greater than 70% and less than or equal to 80% and the stone powder greater than or equal to 20% and less than 30%. The recycled plastic comprises a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). The composition for the recycled plastic composite composition of the present invention can improve the toughness, strength, surface smoothness, heat resistance, and electroplating performance of various products obtained, can be pressed through hydraulic press, results in the increased production, lowered labor, cost for producing various products and decreased pollution.

The present invention further provides a process for the heat-pressing of a recycled plastic composite composition comprising sufficiently mixing pellets of the recycled plastic and the calcium carbonate containing material according to the compositions, set forth below, to create a dry composite mixture. The composite mixture is fed to a screw melting machine, i.e. a mixing machine including electric heating elements. The composite mixture is heated and further mixed to create a thick composite. The thick composite, after being heated, is conveyed to an outlet of the screw melting machine by the screw. The thick composite is obtained at the outlet and conveyed to a hydraulic press, and more specifically a steel mold of a hydraulic press. The amount of thick composite conveyed to the hydraulic press is adapted as needed according to the volume of the mold as well as the volume of the article or device to be molded. The mold, and article or device to be molded is pressed strongly, i.e. maintained under pressure for a period of time. The thick composite is cooled in the steel mold for 5 minutes to 15 minutes and may be cooled further utilizing recirculation of cooling water. Cooling of the thick composite helps to de-mold the thick composite from the mold. The thick composite is then completely immersed in water to be cooled completely to finish the heat-pressing of the thick composite which is now an article or device. The process of heat-pressing the composite of the present invention can improve production efficiency, the surface smoothness, the toughness of the product, the saving of the raw material, improving the heat resistance from −40° C. to −80° C., improve the electroplating performance of various products obtained, results in the decreased pollution.

More specifically, the present invention provides a composition for the recycled plastic composite composition which can improve the toughness, strength, surface smoothness, heat resistance, and electroplating performance of various products obtained, results in the increased production, lowered labor, cost for producing various products and decreased pollution. In order to achieve the subject of the present invention, there is provided the following embodiments: a composition for a recycled plastic composite comprising in the terms of weight percent: a recycled plastic from 30% to 80% and a calcium carbonate containing material from 20% to 70%.

Preferably, the recycled plastic is one or mixture of more in any ratio of a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). In one embodiment, said composition comprises in the terms of weight percent: the recycled plastic greater than 70% and less than or equal to 80% and the calcium carbonate containing material greater than or equal to 20% and less than 30%. In one embodiment, said composition comprises in the terms of weight percent: the recycled plastic greater than 60% and less than or equal to 70% and the calcium carbonate containing material greater than or equal to 30% and less than 40%. In one embodiment, said composition comprises in the terms of weight percent: the recycled plastic greater than 50% and less than or equal to 60% and the calcium carbonate containing material greater than or equal to 40% and less than 50%. In one embodiment, said composition comprises in the terms of weight percent: the recycled plastic greater than 40% and less than or equal to 50% and the calcium carbonate containing material greater than or equal to 50% and less than 60%. In one embodiment, said composition comprises in the terms of weight percent: the recycled plastic greater than 30% and less than or equal to 40% and the calcium carbonate containing material greater than or equal to 60% and less than 70%.

in one embodiment, the talc can be added to any of the composition in an amount from 1% to 15%. In the embodiment including talc, either the weight of the recycled plastic or the weight of the heavy calcium carbonate may be reduced by an amount equal to the weight of the talc, or, a combination of recycled plastic and heavy calcium carbonate, in any ratio of recycled plastic to heavy calcium carbonate, may be reduced by an amount equal to the weight of the talc. In one exemplary embodiment, the composition includes 50% recycled plastic, 48% heavy calcium carbonate, and 2 talc (all percentages by weight).

The technical effects achieved in the present invention through the above mentioned embodiments include improving the toughness, strength, surface smoothness, heat resistance, and electroplating performance of various products obtained, can be pressed through hydraulic press, results in the increased production, lowered labor, cost for producing various products and decreased pollution.

Further, the present invention provides a process of heat-pressing the composite which can improve production efficiency, the surface smoothness, the toughness of the product, the saving of the raw material, improving the heat resistance from −40° C. to −80° C., improve the electroplating performance of various products obtained, results in the decreased pollution. In order to achieve the subject of the present invention, there is provided a process for the heat-pressing of a recycled plastic composite comprising the steps of:

-   -   A. Sufficiently mixing pellets of recycled plastic and calcium         carbonate containing material according to the compositions to         create a composite mixture;     -   B. The composite mixture is fed to a screw melting machine,         heated, and further mixed to create a thick composite. The thick         composite, after being heated, is conveyed to the outlet of the         screw melting machine by the screw;     -   C. The thick composite is obtained at the outlet, conveyed to a         hydraulic press, and more specifically to a steel mold of a         hydraulic press, according to the volume of the mold to be         molded and then pressed strongly;     -   D. The thick composite is cooled in the steel mold for 5 minutes         to 15 minutes with recirculation of cooling water to de-mold the         thick composite. The thick composite is then completely immersed         in water to be cooled completely to finish the heat-pressing of         the composite.         Preferably, the size of the calcium carbonate containing         material is from 600 mesh to 1200 mesh. Preferably, the         temperature in the screw melting machine with electric heating         is controlled to be from 160° C. to 240° C.

The technical effects achieved in the present invention through the above mentioned embodiments include improving production efficiency, the surface smoothness, the toughness of the product, the saving of the raw material, improving the heat resistance from −40° C. to −80° C., improving the electroplating performance of various products obtained, resulting in the decreased pollution. The product of the process of the present invention is the resin article such as flowerpots, picture frames, lamp brackets and lamp sockets, fence of the garden, guard of the garden, gift, furniture decoration, construction decoration, graving article, graving of emulation, and the raw materials for emulation animal and plant graving.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used herein, a “thick composite” means a viscous liquid composite.

The present invention provides a composition for a recycled plastic composite comprising in the terms of weight percent: a recycled EVA from 30% to 80% and a calcium carbonate containing material from 20% to 70%.

As used herein and in the claims, amounts are provided in weight percent based upon total weight of the composition unless expressly stated otherwise.

The recycled plastic, in one embodiment includes recycled EVA and can optionally include one or more of the following: a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). In another embodiment, the recycled plastic can be any one of or mixture of recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene)

The ratio of recycled plastic to the calcium carbonate containing material can be varied and the resulting properties of the composition can depend on the amount of each ingredient used. In certain embodiments, the composition for a high toughness recycled plastic composite composition comprises in the terms of weight percent: the recycled plastic greater than 70% and less than or equal to 80% and the calcium carbonate containing material greater than or equal to 20% and less than 30%. A high toughness recycled plastic composite composition include:

Composition 1: the recycled plastic 80% and the calcium carbonate containing material 20%.

Composition 2: the recycled plastic 71% and the calcium carbonate containing material 29%.

Composition 3: the recycled plastic 75% and the calcium carbonate containing material 25%.

In an alternate embodiment, a composition for a less high toughness recycled plastic composite composition comprises in the terms of weight percent: the recycled plastic greater than 60% and less than or equal to 70% and the calcium carbonate containing material greater than or equal to 30% and less than 40%. A less high toughness recycled plastic composite composition include:

Composition 4: the recycled EVA 70% and the calcium carbonate containing material 30%.

Composition 5: the recycled EVA 65% and the calcium carbonate containing material 35%.

Composition 6: the recycled EVA 61% and the calcium carbonate containing material 39%.

In an alternate embodiment, a composition for a medium toughness recycled plastic composite composition comprises in the terms of weight percent: the recycled plastic greater than 50% and less than or equal to 60% and the calcium carbonate containing material greater than or equal to 40% and less than 50%. A medium toughness recycled plastic composite composition include:

Composition 7: the recycled EVA 60% and the calcium carbonate containing material 40%.

Composition 8: the recycled EVA 55% and the calcium carbonate containing material 45%.

Composition 9: the recycled EVA 51% and the calcium carbonate containing material 49%.

In an alternate embodiment, a composition for a less medium toughness recycled plastic composite composition comprises in the terms of weight percent: the recycled plastic greater than 40% and less than or equal to 50% and the calcium carbonate containing material greater than or equal to 50% and less than 60%. A less medium toughness recycled plastic composite composition include:

Composition 10: the recycled EVA 50% and the calcium carbonate containing material 50%.

Composition 11: the recycled EVA 45% and the calcium carbonate containing material 55%.

Composition 12: the recycled EVA 39% and the calcium carbonate containing material 61%.

In an alternate embodiment, a composition for a low toughness recycled plastic composite composition comprises in the terms of weight percent: the recycled plastic greater than 30% and less than or equal to 40% and the calcium carbonate containing material greater than or equal to 60% and less than 70%. A low toughness recycled plastic composite composition include:

Composition 13: the recycled EVA 40% and the calcium carbonate containing material 60%.

Composition 14: the recycled EVA 35% and the calcium carbonate containing material 65%.

Composition 15: the recycled EVA 31% and the calcium carbonate containing material 69%.

Optionally, talc, or a similar material, can be added to any of the compositions. In certain compositions, talc is added in an amount from 1% to 15% in order to improve the surface smoothness of the article. In this embodiment, either the weight of the recycled plastic or the weight of the heavy calcium carbonate may be reduced by an amount equal to the weight of the talc, or, a combination of recycled plastic and heavy calcium carbonate, in any ratio of recycled plastic to heavy calcium carbonate, may be reduced by an amount equal to the weight of the talc. In one exemplary embodiment, the composition includes 50% recycled plastic, 48% heavy calcium carbonate, and 2 talc (all percentages by weight).

The recycled plastic is pelletized prior to mixing with the calcium carbonate containing material. The method for producing the composite comprises sufficiently mixing pellets of the recycled plastic and the calcium carbonate containing material according to any abovementioned compositions to get a dry composite mixture. The dry composite mixture is fed to a screw melting machine, i.e. a mixing machine including electric heating elements. The composite mixture is heated and further mixed to create a thick composite. In an exemplary embodiment, the composite mixture is heated to between about 160° C. and 240° C. The thick composite, after being heated is conveyed to an outlet of the screw melting machine by the screw. The thick composite is obtained at the outlet and conveyed to a hydraulic press, and more specifically to a steel mold of a hydraulic press. The amount of thick composite conveyed to the hydraulic press is adapted as needed according to the volume of the mold as well as the volume of the article or device to be molded. The mold, and article or device to be molded is pressed strongly, i.e. maintained under pressure for a period of time. The thick composite is cooled in the steel mold for 5 minutes to 15 minutes and may be cooled further utilizing recirculation of cooling water. The thick composite is completely then immersed in the water, i.e. after cooling the temperature thereof, to complete the heat-pressing of the composite. The composition of the present invention is useful in the resin article such as for the manufacturing of flowerpot, frame for the image, lamp bracket and lamp socket, fence of the garden, guard of the garden, unsaturated resin article, gift, furniture decoration, construction decoration, graving article, graving of emulation, and the raw materials for various products.

The present invention provides a process for the heat-pressing of a recycled plastic composite including the steps of:

A. Sufficiently mixing the pellet of the recycled plastic and the calcium carbonate containing material according to the compositions to get a dry composite mixture wherein the mixing can be carried out through a manual or mechanical means. The compositions are as follows:

In a composition for a high toughness recycled plastic composite, the recycled plastic is from 70% to 80% of the mixture by weight, and, the calcium carbonate containing material is from 20% to 30% of the mixture by weight. In a composition for a less high toughness recycled plastic, the recycled plastic is from 60% to 70% of the mixture by weight, and, the calcium carbonate containing material is from 30% to 40% of the mixture by weight. In a composition for a medium toughness recycled, plastic, the recycled plastic is from 50% to 60% and% of the mixture by weight, and, the calcium carbonate containing material is from 40% to 50% of the mixture by weight. In a composition for a less medium toughness recycled plastic, the recycled plastic is from 40% to 50% and of the mixture by weight, and, the calcium carbonate containing material is from 50% to 60% of the mixture by weight. In a composition for a low toughness recycled plastic, the recycled plastic is from 30% to 40% of the mixture by weight, and, the calcium carbonate containing material is from 60% to 70% of the mixture by weight.

B. The composite mixture is fed to a screw melting machine, heated and further mixed to create a thick composite. The thick composite, after being heated, is conveyed to an outlet by the screw of the screw melting machine. The feeding of the composite mixture to the screw melting machine with electric heating can be carried out through a manual or mechanical means.

C. The thick composite is obtained at the outlet, conveyed to a hydraulic press, and more specifically to a steel mold of a hydraulic press. The amount of thick composite conveyed to the hydraulic press is adapted as needed according to the volume of the mold as well as the volume of the article or device to be molded. The mold, and article or device to be molded is pressed strongly, i.e. maintained under pressure for a period of time. The obtaining of the thick composite can be carried out through a manual or mechanical means. Further, the conveying of the thick composite to a steel, mold of the hydraulic press can be carried out through a manual or mechanical means.

D. The thick composite is cooled in the steel mold for 5 minutes to 15 minutes with recirculation of cooling water to assist in de-molding the thick composite. The thick composite is then completely immersed in water to be cooled completely to finish the heat-pressing of the composite.

Preferably, in the example described above, the size of the calcium carbonate containing material is from 600 mesh to 1200 mesh. Preferably, in the example described above, the temperature in the screw melting machine with electric heating is controlled to be between about 160° C. to 240° C.

While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof. 

1.-21. (canceled)
 22. A method of preparing a recycled plastic composite, the method comprising: mixing together components to form a dry composition, the components comprising, based on the total composition: 30 to 80 wt. % of recycled plastic; and 20 to 70 wt. % heavy calcium carbonate; melting the dry composition to form a viscous liquid composite; conveying the viscous liquid composite to a mold; heat pressing the viscous liquid composite in the mold to form a molded composite; recirculating cooling water to de-mold the molded composite to form a de-molded composite; immersing the de-molded composite in water; and completing the heat pressing to obtain the recycled plastic composite.
 23. The method of claim 22, wherein the dry composition is heated to about 160° C. to 240° C.
 24. The method of claim 22, further comprising feeding the dry composition to a screw melting machine with electric heating for melting of the dry composition.
 25. The method of claim 22, wherein recirculating further comprises circulating cooling water about the mold.
 26. The method of claim 22, wherein the recycled plastic comprises ethylene-vinyl acetate copolymer, chlorinated polypropylene, polyvinyl chloride, polyethylene, or a combination thereof.
 27. The method of claim 22, wherein the recycled plastic comprises ethylene-vinyl acetate copolymer.
 28. The method of claim 22, wherein the recycled plastic consists of ethylene-vinyl acetate copolymer.
 29. The method of claim 22, further comprising adding 1 to 15 wt. % talc to the composition.
 30. The method of claim 29, wherein a size of heavy calcium carbonate is from 600 mesh to 1200 mesh.
 31. A method of preparing a recycled plastic composite, the method comprising: mixing together components to form a dry composition, the components comprising, based on the total composition: 30 to 80 wt. % of recycled plastic; 20 to 70 wt. % heavy calcium carbonate; and 1 to 15 wt. % talc; melting the dry composition to form a viscous liquid composite; conveying the viscous liquid composite to a mold of a hydraulic press; heat pressing the viscous liquid composite in the mold to form a molded composite; cooling the molded composite in the mold for 5 to 15 minutes; recirculating cooling water to further cool the molded composite and to de-mold the molded composite to form a de-molded composite; immersing the de-molded composite in water; and completing the heat pressing to obtain the recycled plastic composite.
 32. The method of claim 31, wherein the dry composition is heated to about 160° C. to 240° C.
 33. The method of claim 31, further comprising feeding the dry composition to a screw melting machine with electric heating for melting of the dry composition.
 34. The method of claim 31, wherein the recycled plastic comprises ethylene-vinyl acetate copolymer, chlorinated polypropylene, polyvinyl chloride, polyethylene, or a combination thereof.
 35. The method of claim 31, wherein the recycled plastic comprises ethylene-vinyl acetate copolymer.
 36. The method of claim 31, wherein a size of heavy calcium carbonate is from 600 mesh to 1200 mesh.
 37. A method of forming a molded article, the method comprising: mixing together components to form a dry composition, the components comprising, based on the total composition: 30 to 80 wt. % of recycled plastic; and 20 to 70 wt. % heavy calcium carbonate; melting the dry composition to form a viscous liquid composite; conveying the viscous liquid composite to a mold; heat pressing the viscous liquid composite in the mold to form a molded composite; recirculating cooling water to de-mold the molded composite to form a de-molded composite; immersing the de-molded composite in water; and completing the heat pressing to obtain the molded article.
 38. The method of claim 37, wherein the molded article is a flower pot.
 39. The method of claim 37, further comprising adding 1 to 15 wt. % talc to the composition.
 40. The method of claim 37, wherein the recycled plastic comprises ethylene-vinyl acetate copolymer, chlorinated polypropylene, polyvinyl chloride, polyethylene, or a combination thereof.
 41. The method of claim 37, wherein the molded article is heat resistant between −40° C. to −80° C. 